Cleaner Fly Ash Brick ProductionRaw Materials

• Overview– Source

– Composition

– Quality Parameter

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Types of Raw Materials

Pulverised Fuel Ash (Fly Ash)

Lime Gypsum Cement

Chemical

Admixtures Stone Dust

Pulverised Fuel Ash (Fly Ash)

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Pulverised Fuel Ash (Fly Ash)

ESP Ash / Chimney

Ash / Dry fly AshBottom Ash

Pond Ash /

Mound ash

• Pulverized fuel Ash commonly known as fly Ash is a useful by-product from thermal power stations using pulverized coal as fuel and has considerable pozzolonic activity. More than 150 MT Fly Ash generate by as per More than 400 thermal power Plant in India (CEA Report Dec-2017 ).

• Pulverized fuel ash commonly known as fly ash shall conform to Grade 1 or Grade2 of IS 3812.

• The major portion of the Ashcomes out alongwith the fluegases and is collected throughelectrostatic precipitator this partof Ash is generally known as ESPAsh.

• Bottom Ash tested asaccording to IS 1727.

When pulverized coal

(bituminous/lignite is burnt in the

boiler of a thermal power station, a

part of Ash falls down at the bottom

of the boiler and is known as bottom

Ash.

The residual ESP Ash and

bottom Ash are taken to

lagoons known as Ash

ponds for deposition. The

Ash deposited in the Ash

pond is known as pond

Ash similarly ash stored as

heaps in open is called mound Ash

Lime

Lime

Lime Sludge

• Lime is basically Calcium Oxide (CaO) in natural

association with magnesium oxide (MgO).

• Lime reacts with fly ash at ordinary temperature

and forms a compound possessing cementitious

properties.• Lime shall conform to Class C hydrated lime of 1S712

• Residual of Dry Acetylene gasplants using Calcium Carbide forcutting gas production.

• Available Locally in sludge/ pastefrom with high Caoh2 content.

Hydrated Lime

• Quick Lime when submerged in water for more than 48 hours the heat evaporates as the heat of hydration and the dried lime thus is Pulverised as Hydrated lime powder.

Lime

Quick Lime

• Calcium Oxide, commonly known as quicklime or burnt lime, is a

widely used chemical compound. It is a white, caustic, alkaline,

crystalline solid at room temperature.

• Mostly available in many states like Rajasthan, M.P, Uttarakhand,

North east etc. in form of lime stone rocks.

• Used for refining in industries & paints coloring the national

household. We use the residual of above left over at lime kiln.

• Available in lumps & powder both packed in bags.

• Generally Quick Lime above 70-80% Cao content is preferred for Fly

Ash Bricks.

Gypsum

Gypsum

POP

Gypsum is a rock like mineral commonly

found in the earth’s crust, extracted,

processed and used by Man in construction

or decoration in the form of plaster and

alabaster since 9000 B.C.

Gypsum should be tested for its purity as

per IS 1288 -1982

Gypsum is a soft sulfate mineral composed

of calcium sulfate dehydrate, with the

chemical formula Cao & 2H2O.

It is widely mined and is used as a fertilizer,

and as the main constituent in many forms

of plaster, blackboard chalk and wallboard.

Gypsum can either be turned into gypsum

board or remain in its powder form and be

called "Plaster of Paris" or POP.

Gypsum

Gypsum

Gypsum Rocks

Gypsum as per IS 1288 -1982 Massive gypsum rock forms within layers of sedimentary rock, typically found in thick beds or layers.

It forms in lagoons where ocean waters high in calcium and sulfate content can slowly evaporate and be regularly replenished with new sources of water.

Fluro Phospho

Gypsum

By products of Floron & other refrigeration gases containing high value of calcium sulphates i.e. Caso4

Cement

Cement

Portland cement

A cement is a binder, a substance used forconstruction that sets, hardens and adheres toother materials, binding them together.

Cement is used with fine aggregate to producemortar for masonry or with sand and gravelaggregates to produce concrete.

Ordinary Portland cement conforming to IS 269.

Portland cement is the most common type ofcement in general use around the world as abasic ingredient of concrete, mortar, stucco, andnon-specialty grout. It was developed fromother types of hydraulic lime in England in themid 19th century and usually originates fromlimestone.

OPC Cement as recommended in our BIS 12894& 16720 is used as OPC cement already containsfly ash.

Cement

Cement complying with any of the following Indian

Standards may be used:

1. Ordinary Portland cement, conforming to IS 269

2. Portland slag cement, conforming to IS 455

3. Portland pozzalana cement: fly ash based, conforming to IS

1489 (Part 1)

4. Portland pozzolana cement: calcined clay based,

conforming to IS 1489 (Part 2)

5. Sulphates resisting Portland cement, conforming to IS 12330

6. Super sulphated cement, conforming to IS 6909

7. Rapid hardening Portland cement, conforming to IS 8041

8. White Portland cement, conforming to IS 8042

9. Hydrophobic Portland cement, conforming to IS 8043

10. Composite cement, conforming to IS 16415

Stone dust

Residual of masonry stone dust crushers with minimum silt content as measured in conformation to relevant pries slandered.

Below 6 mm fineness is advise able to allow the chemistry of Lime + Gypsum or Cement flow in a most cohesive way.

Chemical Admixtures

Chemical admixtures, when used shall conform to IS

9103.

Previous experience with and data on such materials

should be considered in relation to the specified

standards of mechanization, supervision and

workmanship in production of pulverized fuel ash

cement bricks.

They may be added for specific requirements without

affecting of specified quality parameters.

The different types of admixtures covered in this standard

are as follows: a) Accelerating admixtures

b) Retarding admixtures

c) Water-reducing admixtures

d) Air-entraining admixtures and - 3 Super plasticizing admixtures.

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Knowledge-based Activism

Together We Can and Together We Will…

Thank You

Though Yesterday was

Red, But Tomorrow

must be Green

It has taken 20 long years to change the colour of brick from to

in architecture, engineering and diploma textbooks

ये नफ़रत बुरी है न पालो इसे, दिलो ों में खदलश है दनकालो इसे।

ना मेरा ना तेरा ना इसका ना उसका, ये सबका वतन है बचा लो इसे

References

• IS 12894:2002 – Pulverized Fuel Ash-Lime Bricks – Specification• IS 3115:1992 – Specification for lime based blocks• IS 10049: 1981 (Reaffirmed 2009) – Code of Practice for Manufacture of Lime

Based Blocks• IS 2541:1991 – Code of practice for preparation and use of lime concrete• IS 4098:1983 – Specification for lime-pozzolana mixture• IS 5817:1992 – Code of practice for preparation and use of lime- pozzolana

mixture concrete in buildings and roads• IS 10359:1982 – Code of practice for manufacture and use of lime- pozzolana

concrete blocks for paving• IS 10360:1982 – Specification for lime-pozzolana concrete blocks for paving• IS 10772:1983 – Specification for quick setting lime pozzolana• IS 12654:1989 – Code of practice for use of low grade gypsum in building

industry• IS 12679:1989 – Specification for By-product gypsum for use in plaster, blocks

and boards• IS 2212:1991 – Code of practice for Brick Works• IS 3495:1992 – Compressive Strength of Brick

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